Dungs FRM 100025, FRM 100050 Instruction Manual

Edition 02.17 • No. 270 442

1 … 64

The target group of this manual is qualied personnel of the gas safety and regulating technology. Due to their specialist training, knowledge and experience, they should be capable of evaluating the work assigned to them and recognising possible dangers. Only they are permitted to carry out assembly, commissioning, settings and maintenance on the devices in compliance with the recognised rules for occupational safety.

Instruction manual

FRM 100025 - 100050

2. Warnings

Never carry out work as long as gas pressure or voltage is applied. Avoid open re. Please observe public regulations.

The device must be protected from vibrations and mechanical impacts.

All adjustments and settings should only

be performed in accordance with the instruction manuals of the connected

machines.

The recognised occupational safety

rules and accident prevention regula-

tions must be observed and, if necessary, personal protective measures must be taken.

Connected line systems must be free from dirt and contamination.

Hang this instruction manual in a readily visible place

inside the installation room! Do not carry out any work

until you have read the safety instructions of this instruction manual and are qualied to do so.

The device may only be operated in

compliance with the operating conditions stated on the type plate.

Prior to assembly, the device must be inspected for transport damage.

The device must not be used in areas

with increased seismic risk.

Protection from environmental impacts and weather conditions (corrosion, rain, snow, icing, humidity (e.g. by condensation), mould, UV radiation, harmful insects, poisonous, corrosive solutions/ liquids (e.g. cutting and cooling uids

must be guaranteed. Depending on the installation site, it may be necessary to

take protective measures.

The device must not be exposed to open re. Protection against lightning strikes must be guaranteed.

2.1 General warnings

1. Target group

Explanation of the symbols

1, 2, 3,... = Order of

action

• = Instruction

2 …64

Edition 02.17 • No. 270 442

2.2 Designated use

The device is used in accordance with its designated use if the following instructions are observed:

• Use of the device in gas transport and gas distribution networks, commercial and industrial plants.

• Use in pressure regulator stations according to EN 12186 and EN 12279.

• Use with gases of the 1st and 2nd gas families according to EN 437 only.

2.3 Risks in case of misuse

• If used in accordance with their designated use, the devices are safe to operate.

• Non-observance of the regulations may result in personal injury or material damage, nancial damage or environmental damage.

3. Approval / declaration of conformity

• Operator errors or misuse present risks to life and limb of the operators and also to the device and other material property.

• Use with dry and clean gases only, no aggressive media.

• Use only in compliance with the operating conditions

stated on the type plate.

• Use in perfect condition only.

• Malfunctions and faults must be eliminated immediately.

• Use only in observance of the instructions given in this

instruction manual and of national regulations.

Edition 02.17 • No. 270 442

3 … 64

4. Table of contents

1. Target group 1

2. Warnings 1

2.1 General warnings 1

2.2 Designated use 2

2.3 Risks in case of misuse 2

3. Approval/declaration of conformity 2

4. Table of contents 3

5. List of abbreviations 4

6. Features 5

6.1 Technical data 5

6.2 Nomenclature 6

6.3 Adjustment ranges 6

6.4 Accuracy class / lock-up pressure class 7

6.5 Selection of regulator springs 8

6.6 Selection of SAV springs 8

6.7 Type plate 9

7. Function 10

8. Dimensions 11

9. Installation 13

9.1 General information 13

9.2 Installation instructions 14

9.3 Torque 14

10. Integrated SAV 16

10.1 Function 16

10.2 Mounting on the regulator 17

11. Setting 18

11.1 Regulator setting 18

11.2 SAV setting 19

11.3 Calculation example of set values 20

11.4 Exchange of regulator springs 21

11.5 Exchange of SAV springs 23

11.5.1 Spring exchange W

dso

11.5.2 Spring exchange W

dsu

12. Commissioning and decommissioning 26

12.1 General information 26

12.2 Leakage test 26

12.3 Commissioning / unlocking / control of the set values 27

12.4 Recommissioning 29

12.5 Decommissioning 29

13. Faults and their causes 29

14. Maintenance 31

14.1 General information 31

14.2 Maintenance instructions of the regulator 33

14.2.1 Preparation 33

14.2.2 Replacement of the working diaphragm 33

14.2.3 Replacement of the control plate / valve seat 37

14.3 Maintenance instructions of the SAV 43

14.3.1 Preparation 45

14.3.2 Removal of the ASE from the housing 45

14.3.3 Check / replacement of the working diaphragm, MD/HD version 46

14.3.4 Check / replacement of the working diaphragm, ND version 49

14.3.5 Mounting of the ASE on the housing 50

14.4 Necessary tools 51

14.5 Leakage test 53

14.6 Recommended maintenance intervals 53

15. Spare parts 54

15.1 List of spare parts of the regulator 55

15.2 List of spare parts of the SAV 56

15.3 Complete regulator sets 57

15.4 Storage conditions 59

16. Flow volume tables 59

16.1 Natural gas ow volume table 60

16.2 Air ow volume tables 61

16.3 Valve ow volume coecient

4 …64

Edition 02.17 • No. 270 442

5. List of abbreviations

Abbreviation

Description

Response pressure group of the upper response pressure

Response pressure group of the lower response pressure

AC Accuracy class

ASE Safety shuto valve (without housing)

Flow volume coecient

DN Nominal diameter

Fail-open The ring valve moves automatically to the open position, if the main diaphragm or the

auxiliary power required for the actuation of the ring valve fails

IS Type: integral strength range

Class A Functional class: the SAV closes if the comparison diaphragm is damaged or the auxiliary power supply

has failed

MOP Maximum admissible operating pressure

Outlet pressure

d, abs.

Output pressure as absolute pressure

Inlet pressure

u, abs.

Inlet pressure as absolute pressure

Upper response pressure

Lower response pressure

max

Maximum operating pressure

zul.

System-specic operating pressure according to the regulator

PN Nominal pressure of the ange PS Maximum admissible pressure SAV Safety shuto valve SBV Safety relief valve

SG Lock-up pressure class

SN Serial number

SZ Closing pressure zone group

Tp. Operating temperature -20 °C ... +60 °C

Specic guide range

Adjustment range for the upper response pressure through regulation of the available adjusting springs

Adjustment range for the lower response pressure through regulation of the available adjusting springs

dso

Specic adjustment range of the adjusting spring installed for the upper response pressure

dsu

Specic adjustment range of the adjusting spring installed for the lower response pressure

Edition 02.17 • No. 270 442

5 … 64

6. Features

6.1. Technical data

Technical data FRM …

Device Spring-loaded medium pressure regulator according to EN 334

Type IS

(integral strength range)

Type of gas Family 1+2+3

Nominal diameters Flange

Connecting anges PN 25 according to EN 1092-1 or ANSI 150 lbs (B16.5)

DN 25 40 50

ANSI 1’’ 1.5’’ 2’’

Admissible pressure load 10 bar (1000 kPa) Max. inlet pressure 10 bar (1000 kPa) Outlet pressure range 30 - 1500 mbar (3-150 kPa)

Minimum dierential pressure

(ND)

270 mbar (27 kPa)

Minimum dierential pressure

(MD)

350 mbar (35 kPa)

Minimum dierential pressure

(HD)

500 mbar (50 kPa)

Materials

Main body housing: cast iron GGG 50 (GJS 400-18 on request) Diaphragm housing: steel Diaphragms: NBR

Ambient temperature -20 °C to + 60 °C

Technical data SAV …

Device Safety shuto valve in compliance with EN14382, class A

Type IS

Response time ≤ 2s

Adjustment range

below W

10 - 1400 mbar (1-140 kPa)

Adjustment range

above W

40 - 3500 mbar (4-350 kPa)

Materials

Main body housing: cast iron GGG 50 (GJS 400-18 on request) Diaphragm housing: Aluminium Diaphragms: NBR

6 …64

Edition 02.17 • No. 270 442

6.3 Adjustment range

Type Connec-

tion

Ver sion

Accuracy

class* [AC]

Lock-up pres-

sure

class* [SG]

Outlet pressure

range W

Lower switching point

SAV

Upper switching point SAV

AG W

FRM 100025 ND DN 25 ND AC 10 SG 20 30-100 mbar

FRM 100025 MD DN 25 MD AC 5/10** SG 20 90-420 mbar

FRM 100025 HD DN 25 HD AC 5 SG 10 400-1500 mbar

FRM 100025 ND / SAV ND DN 25 ND AC 10 SG 20 30-100 mbar 10-115 mbar AG 10 40-240 mbar AG 10

FRM 100025 MD / SAV MD DN 25 MD AC 5/10** SG 20 90-420 mbar 35-400 mbar AG 10 180-800 mbar AG 10

FRM 100025 HD / SAV HD DN 25 HD AC 5 SG 10 400-1500 mbar 150-1400 mbar AG 5 500-3500 mbar AG 5

FRM 100040 ND DN 40 ND AC 10 SG 20 30-100 mbar

FRM 100040 MD DN 40 MD AC 5/10** SG 20 90-420 mbar

FRM 100040 HD DN 40 HD AC 5 SG 10 400-1500 mbar

FRM 100040 ND / SAV ND DN 40 ND AC 10 SG 20 30-100 mbar 10-115 mbar AG 10 40-240 mbar AG 10

FRM 100040 MD / SAV MD DN 40 MD AC 5/10** SG 20 90-420 mbar 35-400 mbar AG 10 180-800 mbar AG 10

FRM 100040 HD / SAV HD DN 40 HD AC 5 SG 10 400-1500 mbar 150-1400 mbar AG 5 500-3500 mbar AG 5

FRM 100050 ND DN 50 ND AC 10 SG 20 30-100 mbar

FRM 100050 MD DN 50 MD AC 5/10** SG 20 90-420 mbar

FRM 100050 HD

DN 50 HD AC 5 SG 10 400-1500 mbar

FRM 100050 ND / SAV ND DN 50 ND AC 10 SG 20 30-100 mbar 10-115 mbar AG 10 40-240 mbar AG 10

FRM 100050 MD / SAV MD DN 50 MD AC 5/10** SG 20 90-420 mbar 35-400 mbar AG 10 180-800 mbar AG 10

FRM 100050 HD / SAV HD DN 50 HD AC 5 SG 10 400-1500 mbar 150-1400 mbar AG 5 500-3500 mbar AG 5

6.2 Nomenclature

Example FRM 100025 ND / SAV ND

FRM 100 025 ND

SAV

Type

Spring-loaded medium pressure regulator

MOP

100 … 10.000 mbar

Nominal diameter

DN 25 025

DN 40 040

DN 50 050

Pressure range, outlet pressure

ND Low pressure

MD Medium pressure

HD High pressure

Safety device

SAV Integrated safety shuto valve

Pressure range, trip pressure

ND Low pressure

MD Medium pressure

HD High pressure

Flange type

ANSI

with standard PN-25 with ANSI 150 lbs

*Accuracy class / lock-up pressure class according to EN 334 **pd = 90-180 mbar: AC 10

pd= 180-420 mbar: AC 5

Edition 02.17 • No. 270 442

7 … 64

6.4 Accuracy class / lock-up pressure class

Version Outlet pressure range Accuracy class [AC] Closing pressure

FRM...ND 30-50 mbar AC 15

+ 15 mbar

50-80 mbar AC 10

90-100 mbar AC 5

FRM...MD 90-120 mbar AC 15

+ 25 mbar

120-180 mbar AC 10

180-420 mbar AC 5

FRM...HD 400-450 mbar AC 10

+ 50 mbar

450-500 mbar AC 5

500-1500 mbar AC 2.5

The AC and SG data, in compliance with EN 334, do not make any statement about the modulation range. Knowledge of the minimum and maximum volume ow is essential for the application in the eld. Therefore, the accuracy values 'control quality' and 'lock-up pressure class' that can be guaranteed at a volume ow of 1:10 were determined.

Abbreviation

Description

AC Accuracy class

Outlet pressure

u1/2

Inlet pressure

Set nominal value of the outlet pressure

SG Lock-up pressure class

min / pu1/2

AC minimum ow volume at a specic inlet pressure pu (lower limit of the volume ow at which the stable operating conditions for a given nominal value within the given operating temperature range).

max / pu1/2

AC maximum ow volume at a specic inlet pressure pu (upper limit of the volume ow at which a given accuracy class for a given nominal value within the given operating temperature range).

The AC values of the table mentioned above refer to the maximum admissible percentage deviation of the outlet pressure from the set nominal value, at which Q

max

/ Q

min

≥ 10

is observed.

min, pu1

min, pu2

max, pu1

max, pu2

x (1-AC/100)

x (1+SG/100)

x (1+AC/100)

8 …64

Edition 02.17 • No. 270 442

Adjustment range, outlet pressure W

Spring colour Order

number

Wire diameter

[mm]

Length

[mm]

Diameter

[mm]

Setpoint range [mbar]

ND MD HD

Silver 270341 5.5 300 60 30-40 90-110

Green 270345 6.5 300 62 40-55 110-170

Yellow 270346 7.0 300 63 55-80 170-240

Blue 270347 8.0 300 65 80-100 240-330

Black 270348 9.0 300 68 330-420 400-580

Purple 270349 10.0 300 69 560-850

Orange 270350 11.0 300 71 800-1200

Pink 270352 12.0 300 73 1100-1500

Specic adjustment range, underpressure W

dsu

Spring colour Order

number

Wire diameter

[mm]

Length

[mm]

Diameter

[mm]

Setpoint range [mbar]

ND MD HD

White 270353 1.2 60 10.0 10-32

Yellow 270355 1.5 55 12.3 24-40

Blue 270356 2.0 55 12.3 30-115 35-110

Black 270357 2.3 55 12.3 50-250

Purple 270358 2.5 55 12.3 80-400 150-500

Orange 270359 2.8 55 12.3 300-1000

Silver 270360 3.0 60 15.0 800-1400

6.5 Selection of regulator springs

6.6 Selection of SAV springs

Specic adjustment range, overpressure W

dso

Spring colour Order

number

Wire diameter

[mm]

Length

[mm]

Diameter

[mm]

Setpoint range [mbar]

ND MD HD

Silver 270361 2.2 60 30.0 40-130

Green 270366 2.5 60 30.0 60-190 180-290

Red 270367 2.7 60 30.0 90-240 230-370

Yellow 270368 3.2 60 30.0 300-500

Blue 270369 3.5 60 30.0 400-800 500-1000

Black 270370 3.7 60 30.0 700-1300

Purple 270371 4.0 60 30.0 1000-1800

Orange 270372 4.5 60 30.0 1300-2500

Pink 270373 4.8 60 30.0 1800-3500

Edition 02.17 • No. 270 442

9 … 64

6.7 Type plate

Abbrevia-

tion

Description

Response pressure group of the upper response pressure

Response pressure group of the lower response pressure

AC Accuracy class

Flow volume coecient for natural gas

DN Nominal diameter

Fail-open The mainvalve moves automatically to the open position, if the main diaphragm or the

auxiliary pressure required for the actuation of the main valve fails

IS SAV type: integral strength range

Class A Functional class: in case the membrane is damaged or in the event of a breakdown of the impulse line pres-

sure the SAV closes

Outlet pressure

Inlet pressure

PN Nominal pressure of the ange PS Maximum admissible pressure SAV Safety shuto valve

SG Lock-up pressure class

-20T60 Operating temperature -20 °C ... +60 °C

SN Serial number

Specic guide range

Adjustment range for the upper response pressure through regulation of the available adjusting springs

Adjustment range for the lower response pressure through regulation of the available adjusting springs

dso

Specic adjustment range of the adjusting spring installed for the upper response pressure

dsu

Specic adjustment range of the adjusting spring installed for the lower response pressure

Regulator SAV

10 …64

Edition 02.17 • No. 270 442

7. Function

The pressure regulator’s function is to keep the outlet pressure largely constant, independent of changes in the inlet pressure and/or in the ow volume. In the depressurised state the regulator is open. The pressure regulator complies with the requirements of EN 334 as gas pressure regulator with standard strength range (IS) and zero ow.

Main components A Control plate B Inlet pressure compensation diaphragm C Lower diaphragm shell D Lever system E Impulse connection for the outlet pressure F Working diaphragm G Vent connection H Setpoint spring

Depressurised state

The force of the setpoint spring H acts on the working diaphragm F. In depressurised state there is no counterforce acting in the lower diaphragm shell C, since no overpressure is applied in the outlet range. The resulting upward movement of the working diaphragm causes the lever system D to be pushed downwards. In this way, the control plate A is then pulled upwards and lifted from the seat. The regulator is open.

Steady state

In case of increasing outlet pressure, the force on the working diaphragm F in the diaphragm shell C increases also. The working diaphragm F is thus pushed upwards until the force of the setpoint spring H is equal to that of the outlet pressure. The upward movement of the working diaphragm F causes the lever system D to be pulled upwards. In this way, the control plate A is then pushed downwards and the valve gap is reduced. The ow volume decreased in this way reduces the outlet pressure until the set nominal value (outlet pressure) is reached again and a balance of forces at the working diaphragm F is established.

If the outlet pressure drops, the force on the working diaphragm F in the lower diaphragm shell C decreases also. The working diaphragm F is, thus, pushed downwards until the force of the setpoint spring H is equal to that of the outlet pressure. The upward movement of the working diaphragm F causes the lever system D to be pushed downwards. In this way, the control plate A is then pulled upwards and the valve gap is reduced. The increased ow volume increases the outlet pressure until the set nominal value (outlet pressure) is reached again and a balance of forces at the working diaphragm F is established.

Inlet pressure compensation

Changes in the inlet pressure have no inuence on the balance of forces. The inlet pressure is compensated by the inlet pressure compensation diaphragm B. The inlet pressure is then transferred in the chamber above the inlet pressure compensation diaphragm B through an opening at the control plate A. At the control plate A, the inlet pressure acts in the opening direction. At the inlet pressure compensation diaphragm B, opposite to the control plate, the inlet pressure acts in the closing direction. The surface of the control plate, on which the inlet pressure acts from below, has the same size as the admission pressure compensation diaphragm B, on which the inlet pressure acts from above. Therefore, both forces cancel each other. The inlet pressure balance at the regulator is ensured.

Edition 02.17 • No. 270 442

11 … 64

8. Dimensions

Type Order

number

max.

[bar/kPa]

DN Dimensions Weight

[kg]

A B C D E F G

FRM 100025 ND 270272 10 / 1000 25 500 184 57 492 820 ⊘ 29.5-1/2“G ⊘12 38

FRM 100025 MD 270273 10 / 1000 25 380 184 57 492 820

⊘ 29.5-1/2“G ⊘12 32

FRM 100025 HD 270274 10 / 1000 25 380 184 57 502 830

⊘ 29.5-1/2“G ⊘12 36

FRM 100040 ND 270278 10 / 1000 40 500 223 69 505 830

⊘ 29.5-1/2“G ⊘12 42

FRM 100040 MD 270279 10 / 1000 40 380 223 69 505 830

⊘ 29.5-1/2“G ⊘12 36

FRM 100040 HD 270280 10 / 1000 40 380 223 69 515 840

⊘ 29.5-1/2“G ⊘12 40

FRM 100050 ND 270284 10 / 1000 50 500 254 80 515 840

⊘ 29.5-1/2“G ⊘12 49

FRM 100050 MD 270285 10 / 1000 50 380 254 80 515 840

⊘ 29.5-1/2“G ⊘12 43

FRM 100050 HD 270286 10 / 1000 50

380 254 80 525 850 ⊘ 29.5-1/2“G ⊘12 47

FRM...

*Ermeto screw connection 12L: GE 12 - 1/4 with screw connection M16 for pipes 12 x 1.5

12 …64

Edition 02.17 • No. 270 442

Type Order

number

p max.

[bar/kPa]

DN Dimensions Weight

[kg]

A B C D E F G

FRM 100025 ND/SAV ND 270275 10 / 1000 25 500 184 232 492 1070 ⊘ 29.5-1/2“G ⊘12 40

FRM 100025 MD/SAV MD 270276 10 / 1000 25 380 184 229 492 1070

⊘ 29.5-1/2“G ⊘12 34

FRM 100025 HD/SAV HD 270277 10 / 1000 25 380 184 236 502 1080

⊘ 29.5-1/2“G ⊘12 38

FRM 100040 ND/SAV ND 270281 10 / 1000 40 500 223 243 505 1080

⊘ 29.5-1/2“G ⊘12 44

FRM 100040 MD/SAV MD 270282 10 / 1000 40 380 223 239 505 1080

⊘ 29.5-1/2“G ⊘12 38

FRM 100040 HD/SAV HD 270283 10 / 1000 40 380 223 247 515 1090

⊘ 29.5-1/2“G ⊘12 42

FRM 100050 ND/SAV ND 270287 10 / 1000 50 500 254 252 515 1090

⊘ 29.5-1/2“G ⊘12 51

FRM 100050 MD/SAV MD 270288 10 / 1000 50 380 254 248 515 1090

⊘ 29.5-1/2“G ⊘12 45

FRM 100050 HD/SAV HD 270289 10 / 1000 50 380 254

256 525 1100 ⊘ 29.5-1/2“G ⊘12 49

FRM... / SAV

*Ermeto screw connection 12L: GE 12 - 1/4 with screw connection M16 for pipes 12 x 1.5

Edition 02.17 • No. 270 442

13 … 64

9. Installation

9.1 General information

• This device can only be installed in compliance with the rules and stand

ards applicable and in accordance with

the local regulations and authorisa tions.

• Install the device in a building or

housing, do not install it outdoors without suitable

protective measures!

• The lifting devices used must be suitable for the load

to be lifted.

• Enough installation space for operation and maintenance has to be provided.

• It is recommended to install a lter with a pore size ≤ 50 µm upstream of the regulator.

• The installation must not impair the functioning of other components.

Check prior to installation!

• Shut-o valves both on the inlet and outlet side are closed.

• Lines are free from combustible gas.

• Prevent explosive gas-air mixture: the room atmosphere

must be monitored for gas leakages.

• Ensure Ensure electrical continuity with use of suitable bonding straps. Prevent contact voltage and ignitable ashover.

• The performance data on the type plate corresponds to the purchase ordering data.

• Flanges on the inlet side and outlet side of the connecting line are parallel.

• The sealing surfaces of the ange are undamaged and clean.

• The maximum inlet pressure of the system is lower than the maximum admissible pressure of the regulator.

• Protective caps at the connection ange, if any, must be removed.

• The minimum distances for the setting must be observed.

• The pipeline on the inlet side must be free of water and

dirt.

Note during installation!

• Mounting must be carried out in a tension-free state.

• Tighten the screws crosswise.

• Tightening torques must be observed.

• Vent lines and blow-o lines have to be positioned sepa-

rately.

• Vent lines and blow-o lines must lead outdoors: gases must be able to escape to a non-hazardous environment.

• The impulse lines may not be shut o.

• The specied distance between the measuring points of

the impulse lines must be observed.

• The ow direction (arrow) on the housing must be followed.

14 …64

Edition 02.17 • No. 270 442

9.2 Installation instructions

• The installation must be carried according to the installation scheme specied below.

• Install the safety shuto valve in the ow direction (arrow/ housing).

• Design a straight stablisation section with the equal diameter.

• Make sure that the impulse tapping at the stablisation section is clean and free from burrs. Distance > 5 x DN

Pos. Designation

1 Shuto valve, inlet side (e.g. ball valve or buttery valve) 2 Filter

3 Welded part

4 Pressure gauge, inlet side 5 Regulator with integrated SAV 6 Calming section 7 SBV 8 Ball valve 9 Pressure gauge, outlet side 10 Test burner 11 Venting ball valve 12 Impulse line, SAV

13 Impulse line, regulator

14 Shuto valve, outlet side (e.g. ball valve or buttery valve) 15 Vent line regulator 16 Vent line SAV 17 Relief line SBV

• Maximum ow velocity in the stablisation section: ≤ 30 m/s.

• Use steel pipe impulse lines D= 12 x 1.5

• Avoid accumulation of condensate: install the impulse

lines with a gradient

Stabilisation section > 5 x DN

Installation drawing

Edition 02.17 • No. 270 442

15 … 64

max.

FRM...

9.3 Torque

The device must not be used as lever.

Use adequate tools!

Tighten the screws crosswise!

[Nm]

ISO 7005-2

DN -- -- -- 25 40 50 65 80 100 125 150 Rp ⅜ ½ ¾ 1 1 ½ 2 2 ½ -- -- -- --

max.

[Nm] t 10 s

70 105 225 340 610 110 1600 2400 5000 6000 7600

max.

[Nm] t 10 s

35 50 85 125 200 250 325 400 -- -- --

Max. torque system accessories M … / G … M 4 M 5 M 6 M8 G ⅛ G ¼ G ½ G ¾

max.

[Nm] t 10 s

2.5 Nm 5 Nm 7 Nm 15 Nm 5 Nm 7 Nm 10 Nm 15 Nm

Max. torque anged joint

Stud

M 12 x 55

(EN 13611)

M 16 x 65 (DIN 939)

max.

[Nm] t 10 s

30 Nm 60 Nm

Mounting position

16 …64

Edition 02.17 • No. 270 442

10. Integrated SAV

SAV protects downstream ttings or lines against pressures that are too high or too low. As soon as the pre-set trip pressure falls below or exceeds a limit due to a fault, the SAV automatically interupts the gas ow. Under normal operating condition the SAV is open. If the equipment downstream of the regulator, including any pipework, cannot safely operate or contain a pressure equal to the highest supply pressure (inlet to regulator), a SAV must be installed. The SAV is designed to shut down the gas supply in the event of a fault condition. The SAV complies with the requirements of EN 14382 as safety shuto valve with standard strength range (IS).

Main components A Valve disc B Closing spring C Ball catch / trigger mechanism D Chamber with the pressure to be monitored E Working diaphragm F Push rod G Setpoint spring for p

H Setpoint spring for p

I Protective cap

Function

Chamber D is connected to the outlet pressure via a pulse line. The pressure to be checked acts on the working diaphragm E. The force of the setpoint springs G and H acts as counter- force. In case of an unbalance of forces (overpressure or underpressure), the SAV is actuated and the gas supply is blocked.

10.1 Function

Edition 02.17 • No. 270 442

17 … 64

10.2 Mounting on the regulator

1. Loosen four hexagonal socket grub screws (M 5x8) of the ASE C using an internal hex key SW 2.5.

2. Remove the base plate A from the housing using a hook wrench 60-90.

3. Remove the O-ring B.

4. Place the new O-ring B of the maintenance kit 6 on the ASE C.

5. Screw the ASE C in the housing using a hook wrench 60-90.

6. Align the Ermeto screw connection D of the pulse connection to the connection of the external pulse line.

7. Tighten four hexagonal socket grub screws (M5x8) in the ASE C using an internal hex key SW 2.5.

18 …64

Edition 02.17 • No. 270 442

11. Setting

11.1 Regulator setting

Setting of the outlet pressure

The regulator is set using the adjusting screw B.

1. Remove the protective cap A.

2. Turn the adjusting screw B using an open-ended wrench SW 24.

3. Turning clockwise: the preload of the setpoint spring is increased and the outlet pressure p

is increased (+).

4. Turning counter-clockwise: the setpoint spring is released and the outlet pressure pds reduced (–).

5. After the setting: screw on the protective cap A again.

(–)

(+)

Edition 02.17 • No. 270 442

19 … 64

(+)

(-)

11.2 SAV setting

Switch-o setting in case of overpressure p

1. Remove the protective cap A.

2. Turn the external adjusting screw B using a socket wrench SW 22.

3. Turning clockwise: increase (+) in the upper shut down

pressure pdo.

4. Turning counter-clockwise: reduction (+) in the upper shut down pressure pdo.

5. After the setting: screw on the protective cap A again.

Triggering setting in case of underpressure p

1. Remove the protective cap A.

2. Turn the internal adjusting screw C using a socket wrench SW 17.

3. Turning clockwise: increase (+) in the lower shut down

pressure pdo.

4. Turning counter-clockwise: reduction (+) in the lower shut down pressure pdo.

5. After the setting: screw on the protective cap A again.

Attention: The setting for lower triggering aects the set value for upper triggering. Please set the vacuum triggering, rst.

A mutual inuence of the pressure regulator and the safety shuto valve must be excluded.

Calculation of the recommended set values according

to the outlet pressure pd of the regulator

• The SAV must lock as soon as it reaches the 1.1 times max. operating pressure according to the system specications.

• The set values of the SAV must be dened taking into account the set values and tolerances of the pressure regulator.

• The tolerances and set values of additional safety devices must also be considered when setting of the SAV.

• In case of a fault or regular shut-down of the downstream shuto valve the SAV may not

be actuated. The upper shut down pressure should be determined to avoid nuisance shut down (e.g. shut down of downstream equipment)

≤ 100 mbar

pdo = pd + 50 mbar

100 mbar < p

≤ 200 mbar

pdo > pd + 100 mbar

> 200 mbar

pdo > pd x 1.5

(+)

(-)

20 …64

Edition 02.17 • No. 270 442

11.3 Calculation example of set values

Determination of the set values by means of a pressure graduation chart

Selected regulator FRM 100025 MD / SAV MD Outlet pressure of the regulator pd 2 0 0 m b a r System-specic operating pressure downstream of the regulator p

zul.

500 mbar

Limiting pressure in case of fault 550 mbar

Accuracy class AC 5

Response pressure group of the upper shut down pressure SAV AGo 10 Response pressure group of the lower shut down pressure SAV AGu 10 Response group of the SBV AG 5

Result

Device group Device data Pressure graduation

Safety devices against excessive pressure

Gas pressure regulator

Safety device against insucient pressure

AGo 10

SAV

AGo 10

AG 5

SBV

AG 5

440 mbar

400 mbar

360 mbar

315 mbar

300 mbar

285 mbar

pd =

pdo =

SG 20

AC 5

FRM

AC 5

210 mbar

200 mbar

190 mbar

pd =

240 mbar

AGu 20

SAV

AGu 20

60 mbar

50 mbar

40 mbar

pdu =

Limiting pressure in case of fault: 1.1 * p

perm.

550 mbar

Edition 02.17 • No. 270 442

21 … 64

11.4 Replacement of regulator springs

Unscrew the sealing cap C from the spring dome us- ing a hinged hook wrench 90-155.

Remove the protective cap A.

Release the setpoint spring E: unscrew the adjusting screw B counter-clockwise until it stops.

Remove the sealing cap C.

(–)

22 …64

Edition 02.17 • No. 270 442

Remove the spring washer D incl. ball.

Remove the setpoint spring E from the spring dome F.

7. Insert a new spring with a suitable adjustment range

8. Reattach the spring washer D incl. ball on the spring.

9. Reinsert the sealing cap C in the spring dome F. Tighten the adjusting screw B until the

required spring preload is reached. Reinsert the protective cap A.

Edition 02.17 • No. 270 442

23 … 64

11.5 Replacement of SAV springs

11.5.1 Spring replacement W

dso

Unscrew the adjusting spring B from the spring dome G using a tube/socket wrench SW 22.

(–)

Remove the protective cap A.

24 …64

Edition 02.17 • No. 270 442

Remove the plastic washer D.

1. Remove the spring E from the spring dome G.

2. Install the new spring.

3. Tighten the adjusting screw B and

the washer D in

the spring dome

G using an open-

ended wrench until the required spring preload is reached.

11.5.2 Spring replacement W

dsu

Remove the adjusting screw C from the inter- nal black spring dome H using an open-ended wrench SW 17.

(–)

Edition 02.17 • No. 270 442

25 … 64

1. Remove the spring

F from the spring

dome.

2. Install the new spring.

3. Tighten the adjusting screw C in the spring dome H us- ing an open-ended wrench SW 17 until the desired spring preload is reached.

Screw on the protective cap A again.

26 …64

Edition 02.17 • No. 270 442

12. Commissioning and decommissioning

12.2 Leakage test

Prior to commissioning

• The performance data on the type plate correspond to the ordering data.

• Prevent explosive gas-air mixture: the room atmosphere must be monitored through gas con-

centration measuring devices for the detection of gas leakages.

• Only operate the device if all safety devices are fully functional.

• Only qualied personnel are allowed to carry out the commissioning.

12.1 General information

Lekspray

pmax = 10 bar

Before commissioning the device, a test for internal and external leakages must be carried out.

1. Test gases of the leakage test: air or inert gases.

2. Upstream and downstream shuto valves must be closed.

3. Release the test section. Check the presence of gas and safely release to the atmosphere.

4. Test pressure > blow-o pressure SBV: block the line upstream of the SBV.

5. Connect the test section to the test device and apply pressure.

6. Test pressure: 1.1 x system-specic operating pressure Maximum PS of the device. Dierent pressure ratings of the system must be taken into account.

7. Observe the waiting time necessary for the pressure compensation according to the system-specic volumes.

External leakage

8. Use a suitable leak detection spray on the device.

9. Monitor the foam formation.

Internal tightness

10. Release the pressure in the test section downstream of

the device.

11. Monitor the increase in pressure on the outlet side: pres-

sure gauge accuracy 0.1 mbar

12. Once the leakage test has been carried out, open the

shuto valve upstream of the SBV.

13. Release pressure in the test section.

Edition 02.17 • No. 270 442

27 … 64

12.3 Commissioning / unlocking/ control of the set values

1. Slowly open the shuto valve on the inlet side. The ball valve on the outlet side remains closed.

2. Monitor the pressure rise on the pressure gauge on the inlet side

upstream of the device.

3. SAV unlocking:

3.4 Compensate pressure by opening the compensation valve on the valve disc: Pull the protective cap A downwards by approx. 2 mm.

3.5 Monitor the pressure rise on the outlet side of the pressure gauge.

3.6 The operating pressure (closing pressure regulator) on the outlet side reached: pull the protective cap A to the stop and lock it.

3.7 SAV is open.

3.8 Unscrew the protective cap A from the push rod and screw it again on the spring dome G.

4.0 Venting

4.1 Vent the test section in the atmosphere by using a suitable hose. Do not use a test burner for venting.

4.2 The test section must be completely lled with gas:

make sure that the test section is free from air by us-

ing a test burner. Close the stop-cock on the venting hose.

5.0 Check of the outlet pressure

5.1 Check the closing pressure of the regulator.

5.2 Open the vent valve and check the set value

(outlet pressure) on the pressure gauge and,

if necessary, correct it according to section 11.1

5.3 Close the vent valve, remove the hose,

insert the sealing cap A.

3.1

Unscrew the protective cap A.

3.2

Reverse the protective cap A and screw it again at the push rod of the SAV.

3.3

Use the protective cap A as a handle.

28 …64

Edition 02.17 • No. 270 442

6.0 Check of the upper shut-down pressure pdo

6.1 SBV installation on the outlet side: block the line upstream of the SBV.

6.2 Check the upper trip pressure of the SAV: create wind load on the outlet side (reduction in

pressure pulse)

6.3 Create a lockable connection between the inlet and outlet side.

6.4 Conduct the inlet pressure in the bypass on the outlet side through the long opening of the stop-cock.

6.5 Monitor the increase in pressure on the outlet side on the pressure gauge.

6.6 Avoid inadmissible high pressure on the outlet side. Stop applying pressure immediately after the SAV has tripped.

6.7 Read the upper response pressure on the pressure gauge on the outlet side and compare it with the nominal value.

6.8 The determined triggering pressure must be within the response tolerance (AGo) of the nominal value.

6.9 If necessary, correct the response pressure according to the specications in section 11.2 and check it again.

7.0 Check of the lower shut down pressure pdu

7.1 Release the pressure in the test section on the outlet side until the operating pressure is reached.

7.2 Check if gas is available and release it safely in the atmosphere.

7.3 Monitor pressure drop on the pressure gauge.

7.4 Unlock SAV.

7.5 Close the shut-o tting on the input side.

7.6 Create the wind load: continue to safely release the gas in the line on the outlet side into the atmosphere.

7.7 After trip the SAV: 6.7 Read the lower response pressure on the pressure gauge on the outlet side and compare it with the nominal value.

7.8 The determined trip pressure must be within the response tolerance (AGu) of the nominal value.

7.9 Close the vent valve, remove the hose, insert the sealing cap.

7.10 Slowly open the shut-o valve on the inlet side.

Pressure release in the test section

Creation of wind load

Edition 02.17 • No. 270 442

29 … 64

Pos. Designation

1 Shut-o valve, inlet side 2 Filter

3 Pressure gauge with pushbutton

4 Venting ball valve 5 Regulator with integrated SAV 6 SBV with shuto valve

Pos. Designation

7 Pressure gauge with pushbutton 8 Venting ball valve 9 Test burner 10 Shut-o valve, outlet side 11 Hose

12.4 Recommissioning

12.5 Decommissioning

1. Close the shuto valve upstream of the bypass.

2. Remove the hose.

3. Open the ball valve upstream of SBV.

1. Slowly close the shuto valve on the outlet side.

2. Slowly close the shuto valve on the inlet side.

13. Faults and related causes

Fault on SAV Possible causes Troubleshooting

It is not possible to open/ activate the SAV.

The impulse line is not installed. Install the impulse line.

The impulse line is clogged. Clean the impulse line.

The impulse line is leaky. Seal the impulse line.

The impulse line is broken. Replace the impulse line.

The impulse pressure is outside the adjustment range.

Set the shut-down pressure of the SAV or the outlet pressure.

The adjusting springs are not suitable for the application. Replace the adjusting springs.

The adjustment range of the SAV is outside the outlet pressure. Replace the SAV or the ASE.

The SAV cannot be activated.

The impulse line is not installed. Connect/install the pulse line.

The impulse line is clogged. Clean the impulse line.

The impulse line is leaky. Seal the impulse line.

The impulse line is broken. Replace the impulse line.

The impulse pressure is outside the adjustment range. Set the shut-down pressure of the SAV.

The adjusting springs are not suitable for the application. Replace the adjusting springs.

The SAV can be activated, but not sealed.

The valve disc is damaged or worn out.

Replace the ASE or have it repaired by DUNGS.

The valve seat is damaged. Replace the valve seat.

The movable parts are contaminated with foreign particles. Clean the movable parts or replace the ASE.

The drive is damaged. Replace the ASE.

The O-ring is damaged. Replace the O-ring or the ASE.

The SAV is leaking towards the atmosphere.

The working diaphragm is damaged.

Change the working diaphragm or replace the ASE.

The sealing ring between the ASE and the housing of the SAV is damaged.

Replace the sealing ring or the ASE.

The O-ring in the ASE is damaged. Replace the O-ring or the ASE.

• Repair work must only be performed by authorized and skilled personnel.

• Only use original spare parts.

4. Slowly open SAV, see section 11.3.

5. Once SAV has been opened completely, open the shuto valve on the outlet side.

3. Check if gas is available in the test section and release it safely into the atmosphere.

30 …64

Edition 02.17 • No. 270 442

Fault on the regulator Possible causes Troubleshooting

There is no gas.

The regulator contains no gas.

Check the gas installation upstream of the regulator.

The SAV is closed. Unlock the SAV.

The regulator provides a wrong outlet pressure.

The false setpoint spring is installed in the regulator. Replace the setpoint spring.

The required outlet pressure is outside the possible range. Change the model of the regulator.

The inlet pressure is not sucient.

Check the gas installation or dismount the regulator again.

With no ow volume the outlet pressure corresponds to the inlet pressure.

The impulse line is not installed. Close the impulse line.

The impulse line is blocked. Check the impulse line.

The impulse line is leaky. Seal the impulse line.

The control plate is damaged. Replace the control plate.

The control plate seat is damaged. Replace the control plate seat.

The working diaphragm is damaged. Replace the working diaphragm.

The admission pressure compensation diaphragm is damaged.

Replace the admission pressure compensation diaphragm.

The lever system is damaged. Replace the lever system.

The O-rings in the regulator are damaged. Replace the O-rings of the regulator.

The O-rings of the SAV are damaged. Replace the O-rings of the SAV.

During operation the outlet pressure corresponds to the inlet pressure.

The pulse impulse is not installed. Close the impulse line.

The pulse impulse is blocked. Check the impulse line.

The pulse impulse is leaky. Seal the impulse line.

The working diaphragm is damaged. Replace the working diaphragm.

The admission pressure compensation diaphragm is damaged.

Replace the admission pressure compensation diaphragm.

The lever system is damaged. Replace the lever system.

The outlet pressure drops if the ow rate of the outlet pressure is increased.

The desired volume ow exceeds the capacity of the regulator.

Start the regulator again and replace it.

False dimensions of the gas installation. Increase the nominal values of the pipeline.

The gas lter upstream of the regulator is soiled. Clean the gas lter, replace the lter mat.

The lever system is damaged. Replace the lever system.

The pulse line is blocked. Check the impulse line.

The SAV is damaged. Check the SAV.

Gas escapes at the vent connection.

The working diaphragm is damaged. Replace the working diaphragm.

The compensation unit is damaged. Replace the control plate.

The O-rings of the compensation axis are leaky. Replace the lever system.

Edition 02.17 • No. 270 442

31 … 64

14. Maintenance

14.1 General information

• The Pressure Equipment Directive (PED) requires the regulator to be

checked at regular intervals to ensure:

safety and correct functioning of the device, high long-term utilisation ratios,

resulting in minimum environmental

impact.

• The maintenance of the device can only be carried

out in compliance with the rules and standards applicable and in accordance with current local regulations.

• Maintenance work must only be performed by au-

thorised and skilled personnel.

• Adhere to the maintenance intervals indicated.

• The risks in case of an escape of ammable or nox-

ious gases into the atmosphere have to be assessed.

• Always install new seals after replacement or modication of parts.

• Only use original spare parts.

• Do not use alcohol-based or solvent-containing

cleaning solutions for cleaning the rubber parts.

Prior to maintenance

• Shut-o valves both on the inlet and outlet side are closed.

• Lines are unstressed and free from combustible gas.

• Prevent explosive gas-air mixture: the room atmosphere

must constantly be monitored through gas concentration measuring devices for the detection of gas leakages.

• SAV is in the closing position.

• Original spare parts are available.

Pos. Designation

A Protective cap

B Adjusting screw

C Sealing cap

D Spring washer with ball

E Setpoint spring

F Diaphragm hood

Hexagon screws + nut

washer

H O-ring (HD version only)

I Reducing washer (HD version only)

J Locking nut

K Spring washer

L Locking spring

M Working diaphragm

N Guide rod

O Lower diaphragm shell P Lower diaphragm disc

Q Sealing ring

R Connection pin

S Control plate

T O-ring

U Control plate sleeve V Valve disc seat

W ... O-ring

X Housing

Y Hexagon screws + washer

32 …64

Edition 02.17 • No. 270 442

W ...

Edition 02.17 • No. 270 442

33 … 64

14.2 Maintenance instructions of the regulator

14.2.1 Preparation

Loosen the screws G (M10) using an open-ended wrench SW 17.

Loosen the loops using an open-ended wrench

SW 17.

14.2.2 Replacement of the working diaphragm

4. Unscrew the sealing cap C from the spring dome using a jointed hook wrench 90-155.

5. Remove the spring washer D incl. ball and the setpoint spring E.

1. Loosen the impulse line and the vent line and remove them.

2. Remove the protective cap A.

3. Completely release the setpoint spring at the adjusting screw B using an open-ended wrench

SW 24.

(–)

34 …64

Edition 02.17 • No. 270 442

Remove the upper diaphragm shell F.

Remove the O-ring H (HD version only).

Remove the reducing washer I (HD version only).

Remove the upper diaphragm shell F.

FRM...MD/HD

FRM...ND

FRM...HD

Edition 02.17 • No. 270 442

35 … 64

Loosen the nut J (M 8) using an open-ended wrench SW 13.

Remove the spring washer K.

FRM...MD/HD

FRM...ND

FRM...MD/HD FRM...ND

Loosen the nut J (M 8) using an open-ended wrench SW 13.

Remove the spring washer K.

36 …64

Edition 02.17 • No. 270 442

Remove the safety spring L.

Remove the working diaphram M from the guide rod N and check for signs of damage or wear. If necessary, reassemble a new working diaphragm M (maintenance kit 2).

FRM...MD/HD

FRM...ND

FRM...MD/HD FRM...ND

Remove the safety spring L.

Remove the working diaphram M from the guide rod N and check for signs of damage or wear. If necessary, reassemble a new working diaphragm M (maintenance kit 2).

Edition 02.17 • No. 270 442

37 … 64

14.2.3 Replacement of the control plate / valve seat

4 Loosen the screws Y.

Remove the lower diaphragm shell O from the housing X. To do this, the diaphragm shell O has to be turned carefully.

Remove the O-ring Q from the lower diaphragm shell O.

38 …64

Edition 02.17 • No. 270 442

Remove the O-ring T from the housing X. Clean the inside of the regulator housing X.

Remove the assembly of the control plate S incl. the sleeve U from the housing X.

Remove the control plate S from the control plate sleeve U and check it for damage. If necessary, replace the control plate S incl. the sleeve U.

Check the valve seat V for dirt or damage.

Edition 02.17 • No. 270 442

39 … 64

If necessary, replace the valve seat V: screw out the valve seat V from the housing X by using a socket wrench.

Tighten the new valve seat V with the new O-ring W (maintenance set 4) in the housing X.

Place the new O-ring T (maintenance kit 3 or 5) in the turned groove in the housing X.

Insert the control plate S with the sleeve U (maintenance set 3) in the housing X again.

40 …64

Edition 02.17 • No. 270 442

Put the diaphragm shell O in position: Secure the lower diaphragm shell O using the lower diaphragm disc P (to do this, the diaphragm disc is dragged upwards) and t the connection pin R. Lock the connection pin R of the valve disc in the coupling of the lever system in the diaphragm shell O by turning it cautiously.

Attention: Risk of crushing!

Place ngers at the marked positions (ê). Fingers may be squeezed between the diaphragm disc P and the diaphragm shell O. Do not slide ngers under the diaphragm disc!!

Make sure that the connection pin R 45° is oriented opposite to the direction of the ow (non-aligned!)

Insert the new O-ring Q (maintenance kit 3, 4 or 5) in the turned groove in the lower diaphragm shell O using grease if necessary to hold it in place.

Edition 02.17 • No. 270 442

41 … 64

When the connection pin R is locked in the lever system Z, both middle lever arms are pushed upwards ( ). To do this, ( ) push the lower diaphragm disc P downwards.

Attention: Risk of crushing!

42 …64

Edition 02.17 • No. 270 442

Fix the diaphram housing O by tightening the 4 screws Y.

Reinsert the diaphragm disc I (HD version only) (maintenance set 2). Insert the new O-ring H (HD only) (maintenance set 2) in the turned groove of the diaphragm disc I. Put on the upper diaphragm hood F.

Re-t the diaphram cover using the 20 o G (M10 screws) with an open ended spanner SW 16. Insert

the setpoint spring E in the spring dome F. Insert the spring washer D incl. ball on the spring. Tighten

the sealing cap C in the spring dome F. Tighten the adjusting screw B such that the required preload is reached. Install the protective cap A.

Reinsert the working diaphragm M on the guide rod

N. Put on the safety spring L and the spring washer K. Screw on the nut J (M 8).

Tighten to the stop using an open-ended screw SW 13.

Edition 02.17 • No. 270 442

43 … 64

14.3 Maintenance instructions of the SAV

ASE...MD/HD

ASE...ND

44 …64

Edition 02.17 • No. 270 442

Pos. Designation

A Diaphragm shell

B Push rod

C O-ring of the diaphragm shell

D Lower diaphragm disc

E Working diaphragm

F Setpoint spring of the lower shut-down pressure

G Upper diaphragm disc (HD version only)

H Allen screw, 6 pieces

I Spring dome ASE

J Over pressure adjustment nut

K Under pressure adjustment nut

L Protective cap

M Housing ASE

N O-ring

O Connecting piece ASE/housing P Hexagonal socket grub screws, 4 pieces

Q ASE

Edition 02.17 • No. 270 442

45 … 64

(–)

1. Remove the impulse and vent lines.

2. Remove the protective cap L.

3. Release the setpoint springs at the adjusting screws J and K.

(–)

13.3.2 Removing the ASE from the housing

14.3.1 Preparation

Loosen four hexagonal socket grub screws (M5x8) using an internal hex key

SW 2.5.

Remove the ASE Q from the housing using a hook

wrench 60-90.

46 …64

Edition 02.17 • No. 270 442

Remove the ASE Q.

14.3.3 Check / replacement of the working diaphragm, MD/HD version

Loosen the six Allen screws H (M5) using an internal hex key SW 4.

Remove the cover I of the ASE Q.

Edition 02.17 • No. 270 442

47 … 64

Rremove the under pressure set point spring F from push rod B and then clean it.

Remove the thin diaphragm ring G (HD version only).

Remove the working diaphragm E.

Remove the thick diaphragm ring D.

48 …64

Edition 02.17 • No. 270 442

Insert the new O-ring C (maintenance set 7) in the turned groove of the diaphragm shell A.

Reinsert the diaphragm ring D with the turned groove upwards.

Check the state of the working diaphragm E. If necessary, replace with a new working diaphragm (maintenance set 2).

Insert the working diaphragm E on the push rod B. Place the external bead of the working diaphragm E in the turned groove of the diaphragm ring D.

Reinsert the working diaphragm G with chamfer upwards (HD version only).

Re t the under pressure setpoint spring F on the push rod B.

Re t the ASE cover I.

Tighten the 6 Allen screws H (M5), in order to lock the ASE Q .

Remove the O-ring C and clean the push rod B.

Edition 02.17 • No. 270 442

49 … 64

14.3.4 Check / replacement of the working diaphragms, ND version

Loosen the six Allen screws H (M5) using an internal hex key SW 4.

Remove the cover I of the ASE Q.

Remove the setpoint spring F for lower shut-down pressure from the push rod B and then clean it.

Remove the working diaphragm E.

50 …64

Edition 02.17 • No. 270 442

14.3.4 Mounting of the ASE on the housing

Remove the diaphragm ring D.

Remove the O-ring C. Clean the push rod B.

Insert the new O-ring C (maintenance set 7) in the turned groove of the diaphragm shell K.

Reinsert the diaphragm ring D with the turned groove upwards.

Check the state of the working diaphragm E. If necessary, reassemble a new working diaphragm E (maintenance set 2).

Insert the working diaphragm E on the push rod B. Place the external bead of the working diaphragm E in the turned groove of the diaphragm ring D.

Place the setpoint spring F for lower shut down pressure on the push rod B.

Re t the ASE cover I.

Tighten the 6 Allen screws H (M5), in order to lock the ASE Q .

Place the new O-ring N (maintenance kit 4 or 5) in the turned groove in the housing M.

Tighten the threads of the connecting piece O in the housing M using a hook wrench 60-90.

Fix the connecting piece O of the ASE Q using 4 hexagonal socket grub screws P (M5x8).

Edition 02.17 • No. 270 442

51 … 64

14.4 Required tools

Work step Tool designation

Pressure

rating

Wrench size

DN 25 DN 40 DN 50

1 Loosen the pulse lines. Open-ended spanner (A) ND/MD/HD SW 24 SW 24 SW 24

2 Release the setpoint springs.

Tube/socket wrench (B)

ND/MD/HD

SW 17 SW 17 SW 17

Tube/socket wrench (B) SW 22 SW 22 SW 22

3 Loosen ASE from the housing.

Internal hex key (C1)

ND/MD/HD

SW 2.5 SW 2.5 SW 2.5 Jointed hook wrench with pins according to DIN 1810 (D) 60-90 60-90 60-90

4 Replace the working diaphragm on the ASE. Internal hex key (C2) ND/MD/HD SW 4 SW 4 SW 4

A B

SAV

Order no. 271170

52 …64

Edition 02.17 • No. 270 442

Work step Tool designation

Pressure

rating

Wrench size

DN 25 DN 40 DN 50

1 Loosen the pulse lines. Open-ended spanner (A) ND/MD/HD SW 24 SW 24 SW 24

Release the setpoint springs.

Open-ended spanner (A)

ND/MD/HD

SW 24 SW 24 SW 24

Hinged hook wrench (D) 90-155 90-155 90-155

3 Replace the working diaphragm.

Open-ended spanner (A)

ND/MD/HD

SW 17 SW 17 SW 17

Open-ended spanner (A) SW 13 SW 13 SW 13

4 Replace the control plate. Open-ended spanner (A) ND/MD/HD SW 13 SW 17 SW 17

5 Replace the valve seat. Tube socket wrench (B)/ valve wrench (E) ND/MD/HD SW 30 SW 46 D 60

Regulator

Edition 02.17 • No. 270 442

53 … 64

14.5 Leakage test

14.6 Recommended maintenance intervals

Max. inlet pressure [bar] Functional test Maintenance

> 0.1 to 1 every 4 years every 8 years

> 1 to 5 every 2 years every 4 years

> 5 once a year every 2 years

Lekspray

pmax = 10 bar

After maintenance or repair work, the device must be checked for internal and external leakages.

1. Test gases of the leakage test: air or inert gases.

2. Upstream and downstream shuto valves must be closed.

3. Test pressure > blow-o pressure SBV: block the line upstream of the SBV.

4. Connect the test section to the test device and apply pressure.

5. Test pressure: 1.1 x system-specic operating pressure Maximum PS of the device (SAV 100… 10 bar/SAV 60…6 bar). Dierent pressure ratings of the system must be taken into account.

6. Observe the waiting time necessary for the pressure compensation according to the system-specic volumes.

External leakage

7. Use a suitable leak detection spray on the device.

8. Monitor the foam formation.

Internal tightness

9. Remove the pressure in the test section downstream of

the device.

10. Monitor the increase in pressure on the outlet side: pres-

sure gauge accuracy 0.1 mbar

11. Once the leakage test has been carried out, open the

shuto valve upstream of the SBV.

12. Release pressure in the test section.

13. Check the correct functioning and set values (see

section 11.3.).

1. The maintenance intervals depend on the system-spe-

cic operating and environmental conditions, gas quality, state of the pipelines, etc.

2. The maintenance intervals have to be set by the system

operator according to the system requirements.

3. It is recommended to perform a functional test on a monthly base and carry out maintenance works every year, in order to guarantee the system availability.

4. It is necessary to comply at least with the maintenance intervals specied in G 495.

54 …64

Edition 02.17 • No. 270 442

15. Spare parts

Edition 02.17 • No. 270 442

55 … 64

15.1 List of spare parts of the regulator

Kit Spare part Version Order number Spare part / image

Protective cap

FRM 100025-100050 270396

Working diaphragm with O-ring

FRM 100025-100050 ND 270384

FRM 100025-100050 MD 270385

FRM 100025-100050 HD 270386

Compen-

sation unit

with O-rings

FRM 100025 ND FRM 100025 MD FRM 100025 HD

270387

FRM 100040 ND FRM 100040 MD FRM 100040 HD

270388

FRM 100050 ND 270389

FRM 100050 MD FRM 100050 HD

271092

Valve seat

with sealing

ring and O-ring

FRM 100025 ND FRM 100025 MD FRM 100025 HD

270390

FRM 100040 ND FRM 100040 MD FRM 100040 HD

270391

FRM 100050 ND FRM 100050 MD FRM 100050 HD

270392

Kit

O-rings

FRM 100025 ND FRM 100025 MD FRM 100025 HD

270393

FRM 100040 ND FRM 100040 MD FRM 100040 HD

270394

FRM 100050 ND FRM 100050 MD FRM 100050 HD

270395

E+F

+ +H+I+

G+H

56 …64

Edition 02.17 • No. 270 442

Kit Spare part Version Order number Spare part / image

Protective cap

SAV 100025-100050 ND/MD/HD

SAV 6010-6020 ND/MD/HD

on request

Working diaphragm with O-ring

SAV 100025-100050 ND SAV 6010-6020 ND

on request

SAV 100025-100050 MD SAV 6010-6020 MD on request

SAV 100025-100050 HD SAV 6010-6020 HD

on request

ASE with

o-ring

SAV 100025 ND SAV 6010 ND SAV 6015 ND

270375

SAV 100025 MD SAV 6010 MD SAV 6015 MD

270376

SAV 100025 HD SAV 6010 HD SAV 6015 HD

270377

SAV 100040 ND SAV 6020 ND

270378

SAV 100040 MD SAV 6020 MD

270379

SAV 100040 HD SAV 6020 HD

270380

SAV 100050 ND 270381 SAV 100050 MD 270382 SAV 1000050 HD 270383

15.2 List of spare parts of SAV

Edition 02.17 • No. 270 442

57 … 64

Version

Order

number

Contents

FRM 100025 ND 271093

FRM 100025 MD 271094

FRM 100025 HD 271095

FRM 100040 ND 271096

FRM 100040 MD 271097

FRM 100040 HD 271098

D E+F

15.3 Complete regulator sets

D E+F

C D+E

D E+F

C D+E

58 …64

Edition 02.17 • No. 270 442

Version

Order

number

Contents

FRM 100050 ND 271095

FRM 100050 MD 271098

FRM 100050 HD 271101

D E+F

C D+E

Edition 02.17 • No. 270 442

59 … 64

16. Flow volume tables

Flow volume [Nm3/h]

-10%

+10%

max. ow volume (AC 10)

Setpoint

min. ow volume (AC 10)*

* min. ow volume = 0.1 * max. ow volume

SZ10

15.3 Storage conditions

Basically, DIN 7716 (standards for storage, maintenance and cleaning of rubber products) applies to the storage of diaphragms and O-rings.

The ageing process mostly depends on

the following factors:

• Temperature

• Thermal radiation

• Solar radiation

• Humidity

• Relative humidity

• Ozone

• Stress conditions of the components

Proper storage

• Storage temperature between 5° C and 20° C

• No direct solar radiation

• No direct heat sources in the storage area

• No exposure to ozone

• Tension-free storage

• Storage in polyethylene bags

• Do not exceed the max. storage periods of 3 years

60 …64

Edition 02.17 • No. 270 442

16.1 Natural gas ow volume tables

FRM 100040 … DN 40 - max. ow volume

[Nm3/h]

natural gas of density 0.81 kg/m³ (AC 10)

FRM 100025 … DN 25 - max. ow volume

[Nm3/h]

natural gas of density 0.81 kg/m³ (AC 10)

FRM... ND MD HD

[bar]

pu [bar]

0,03 0,05 0,075 0,1 0,15 0,2 0,25 0,3 0,35 0,4 0,5 0,75 1 1,25 1,5

0,5 297 359 359 371 334 334 334 334 0,75 322 396 445 557 421 433 433 433 433

1 346 433 569 705 495 507 507 544 582 582 582

1,5 396 557 681 804 569 656 656 668 730 755 767 779 916

2 433 656 779 891 681 767 767 792 866 903 953 1015 1039 1039 1089

2,5 513 718 866 990 761 866 866 928 990 1039 1076 1262 1274 1274 1361 3 569 779 965 1101 829 953 953 1027 1101 1163 1163 1423 1608 1608 1608 3,5 625 829 1064 1200 885 1039 1039 1151 1225 1274 1287 1646 1757 1769 1856

4 668 866 1175 1274 934 1114 1114 1262 1361 1398 1411 1745 1905 1967 2103

4,5 705 928 1299 1361 977 1188 1188 1361 1485 1509 1522 1905 2054 2140 2351

5 755 990 1398 1460 1015 1262 1262 1448 1584 1608 1621 2066 2215 2326 2536

6 866 1114 1534 1670 1114 1386 1411 1633 1794 1794 1856 2351 2462 2660 2846

7 977 1225 1646 1831 1213 1460 1559 1794 1967 1955 2079 2623 2747 2969 3093

8 1076 1324 1745 1918 1287 1509 1670 1943 2165 2091 2252 2846 2994 3217 3279

9 1151 1411 1794 1955 1336 1547 1757 2091 2326 2215 2413 3093 3217 3403 3464

10 1175 1472 1819 2004 1373 1571 1831 2202 2475 2239 2487 3229 3403 3526 3600

FRM ... NP MD HD

[bar]

pu [bar]

0,03 0,05 0,075 0,1 0,15 0,2 0,25 0,3 0,35 0,4 0,5 0,75 1 1,25 1,5

0,5 186 217 229 235 192 186 173 161 0,75 198 266 285 297 235 240 224 223 210

1 210 297 346 359 273 306 308 325 313 297 285

1,5 223 322 433 458 371 377 396 371 384 384 371 384 396

2 235 346 507 532 445 445 445 445 483 445 445 445 445 458 470

2,5 247 371 569 594 507 507 582 594 606 557 557 557 557 557 557 3 272 396 631 656 557 582 681 693 730 643 643 643 643 643 643 3,5 297 421 693 705 594 656 779 779 841 705 755 792 792 792 792

4 309 445 755 755 631 718 866 866 940 792 891 940 940 940 940

4,5 322 470 804 804 656 767 953 965 1039 866 990 1052 1076 1076 1089

5 334 495 841 854 681 817 1027 1052 1126 928 1064 1151 1175 1175 1237

6 346 507 866 891 718 891 1114 1175 1287 1052 1237 1336 1423 1423 1423

7 346 520 891 940 742 977 1175 1336 1411 1163 1373 1509 1608 1608 1608

8 359 532 916 977 767 1052 1237 1398 1509 1274 1485 1658 1732 1732 1732

9 359 544 940 1015 792 1089 1287 1460 1621 1349 1596 1794 1794 1794 1794

10 371 557 965 1052 817 1138 1312 1509 1695 1411 1707 1881 1881 1881 1881

Edition 02.17 • No. 270 442

61 … 64

FRM 100025... DN25 - max. air ow volume

[Nm3/h]

(AC 10)

16.2 Air ow volume tables

FRM 100050 … DN 50 - max. ow volume

[Nm3/h]

natural gas of density 0.81 kg/m³ (AC 10)

FRM ... ND MD HD

[bar]

pu [bar]

0,03 0,05 0,075 0,1 0,15 0,2 0,25 0,3 0,35 0,4 0,5 0,75 1 1,25 1,5

0,5 150 175 185 190 155 150 140 130 0,75 160 215 230 240 190 194 181 180 170

1 170 240 280 290 221 247 249 263 253 240 230

1,5 180 260 350 370 300 305 320 300 310 310 300 310 320

2 190 280 410 430 360 360 360 360 390 360 360 360 360 370 380

2,5 200 300 460 480 410 410 470 480 490 450 450 450 450 450 450 3 220 320 510 530 450 470 550 560 590 520 520 520 520 520 520 3,5 240 340 560 570 480 530 630 630 680 570 610 640 640 640 640

4 250 360 610 610 510 580 700 700 760 640 720 760 760 760 760

4,5 260 380 650 650 530 620 770 780 840 700 800 850 870 870 880

5 270 400 680 690 550 660 830 850 910 750 860 930 950 950 1000

6 280 410 700 720 580 720 900 950 1040 850 1000 1080 1150 1150 1150

7 280 420 720 760 600 790 950 1080 1140 940 1110 1220 1300 1300 1300

8 290 430 740 790 620 850 1000 1130 1220 1030 1200 1340 1400 1400 1400

9 290 440 760 820 640 880 1040 1180 1310 1090 1290 1450 1450 1450 1450

10 300 450 780 850 660 920 1060 1220 1370 1140 1380 1520 1520 1520 1520

FRM... ND MD HD

[bar]

pu [bar]

0,03 0,05 0,075 0,1 0,15 0,2 0,25 0,3 0,35 0,4 0,5 0,75 1 1,25 1,5

0,5 198 210 285 285 260 260 260 260 0,75 247 272 334 334 371 396 396 396 396

1 272 322 408 408 483 495 507 507 544 470 470

1,5 303 371 483 483 594 656 656 693 829 582 582 656 761

2 334 408 569 569 705 779 779 866 1076 742 742 866 866 866 928

2,5 365 445 668 668 804 903 903 1015 1237 916 953 1089 1114 1114 1163 3 396 495 718 718 891 1027 1027 1138 1361 1064 1213 1287 1336 1336 1386 3,5 427 532 767 767 965 1101 1151 1274 1460 1188 1349 1485 1534 1534 1608

4 452 582 792 792 1052 1175 1250 1386 1559 1287 1485 1633 1707 1707 1881

4,5 470 631 854 854 1138 1213 1336 1485 1608 1386 1596 1782 1856 1856 2029

5 507 674 916 916 1213 1287 1411 1571 1670 1460 1670 1893 1955 2004 2153

6 582 742 990 990 1312 1398 1534 1707 1794 1596 1806 1943 2054 2202 2425

7 643 817 1064 1076 1411 1497 1646 1794 1918 1707 1905 1980 2140 2400 2673

8 705 878 1126 1151 1485 1571 1732 1881 2042 1794 1980 2017 2239 2635 2895

9 767 928 1175 1213 1547 1633 1819 1930 2165 1856 2029 2054 2314 2772 3007

10 841 977 1225 1299 1608 1707 1868 1967 2289 1893 2079 2079 2351 2895 3106

62 …64

Edition 02.17 • No. 270 442

FRM 100050... DN50 - max. air ow volume

[Nm3/h]

(AC 10)

FRM 100040... DN40 - max. air ow volume

[Nm3/h]

(AC 10)

FRM... ND MD HD

[bar]

pu [bar]

0,03 0,05 0,075 0,1 0,15 0,2 0,25 0,3 0,35 0,4 0,5 0,75 1 1,25 1,5

0,5 240 290 290 300 270 270 270 270 0,75 260 320 360 450 340 350 350 350 350

1 280 350 460 570 400 410 410 440 470 470 470

1,5 320 450 550 650 460 530 530 540 590 610 620 630 740

2 350 530 630 720 550 620 620 640 700 730 770 820 840 840 880

2,5 415 580 700 800 615 700 700 750 800 840 870 1020 1030 1030 1100 3 460 630 780 890 670 770 770 830 890 940 940 1150 1300 1300 1300 3,5 505 670 860 970 715 840 840 930 990 1030 1040 1330 1420 1430 1500

4 540 700 950 1030 755 900 900 1020 1100 1130 1140 1410 1540 1590 1700

4,5 570 750 1050 1100 790 960 960 1100 1200 1220 1230 1540 1660 1730 1900

5 610 800 1130 1180 820 1020 1020 1170 1280 1300 1310 1670 1790 1880 2050

6 700 900 1240 1350 900 1120 1140 1320 1450 1450 1500 1900 1990 2150 2300

7 790 990 1330 1480 980 1180 1260 1450 1590 1580 1680 2120 2220 2400 2500

8 870 1070 1410 1550 1040 1220 1350 1570 1750 1690 1820 2300 2420 2600 2650

9 930 1140 1450 1580 1080 1250 1420 1690 1880 1790 1950 2500 2600 2750 2800

10 950 1190 1470 1620 1110 1270 1480 1780 2000 1810 2010 2610 2750 2850 2910

FRM... ND MD HD

[bar]

pu [bar]

0,03 0,05 0,075 0,1 0,15 0,2 0,25 0,3 0,35 0,4 0,5 0,75 1 1,25 1,5

0,5 160 170 230 230 210 210 210 210 0,75 200 220 270 270 300 320 320 320 320

1 220 260 330 330 390 400 410 410 440 380 380

1,5 245 300 390 390 480 530 530 560 670 470 470 530 615

2 270 330 460 460 570 630 630 700 870 600 600 700 700 700 750

2,5 295 360 540 540 650 730 730 820 1000 740 770 880 900 900 940 3 320 400 580 580 720 830 830 920 1100 860 980 1040 1080 1080 1120 3,5 345 430 620 620 780 890 930 1030 1180 960 1090 1200 1240 1240 1300

4 365 470 640 640 850 950 1010 1120 1260 1040 1200 1320 1380 1380 1520

4,5 380 510 690 690 920 980 1080 1200 1300 1120 1290 1440 1500 1500 1640

5 410 545 740 740 980 1040 1140 1270 1350 1180 1350 1530 1580 1620 1740

6 470 600 800 800 1060 1130 1240 1380 1450 1290 1460 1570 1660 1780 1960

7 520 660 860 870 1140 1210 1330 1450 1550 1380 1540 1600 1730 1940 2160

8 570 710 910 930 1200 1270 1400 1520 1650 1450 1600 1630 1810 2130 2340

9 620 750 950 980 1250 1320 1470 1560 1750 1500 1640 1660 1870 2240 2430

10 680 790 990 1050 1300 1380 1510 1590 1850 1530 1680 1680 1900 2340 2510

Edition 02.17 • No. 270 442

63 … 64

Type of gas

Natural gas

City gas

LPG

Air

0.65

0.47

1.67

1.00

1.24

1.46

0.77

1.00

Air density

spec. weight of the gas used

f =

° V

gas used

air

x f

Density

[kg/m

]

0.81

0.58

2.08

1.24

The maximum indicated volume ow refers to natural gas with a density 0.81 kg/m3 or to air with a density of 1.24 kg / m3 at 15 °C under standard conditions. In case of dierent types of gases, a conversion of the volume ow according to the equation below is carried out.

16.3 Valve ow volume coecient K

Type DN KG-value

FRM 100025... 25 370

FRM 100040... 40 815

FRM 100050... 50 1150

The valve ow volume coecient KG f FRM is equal to the ow volume for a completely open ring valve with an absolute

inlet pressure of p

u, abs.

= 2.01325 bar and absolute outlet pressure of p

d, abs.

= 1.01325 bar. The KG-value value refers to natural

gas with a density ratio of d= 0.64 according to a standard density of pn= 0.83 kg/m3 and gas inlet temperature of t= 15 °C

The mass ow through a nozzle increases at constant upstream pressure with sinking pressure downstream of the nozzle, until it reaches its maximum at critical pressure ratio and remains constant from that moment on. At constant outlet pressure, further increase of the upstream pressure causes a mass ow increase through the regulator. Therefore, to calculate the mass ow through a nozzle, a distinction is made between two ranges:

a) subcritical or critical pressure ratio

b) supercritical pressure ratio

with

QN= power of the regulator under standard conditions

(pd+1,013)*(pu-pd)

KG =

(pu+1,013)

KG =

d, abs.

u, abs.

≥ 0,53

< 0,53

d, abs.

u, abs.

Abbreviation

Description

[bar] Outlet pressure

d, abs.

[bar] Outlet pressure

as absolute pressure (pd+1,013)

pu [bar] Inlet pressure

u, abs.

[bar] Inlet pressure

as absolute pressure (pu+1,013)

64 …64

Edition 02.17 • No. 270 442

Karl Dungs GmbH & Co. KG Karl-Dungs-Platz 1 D-73660 Urbach,

Germany

Phone +49 (0)7181-804-0 Fax +49 (0)7181-804-166 e-mail: info@dungs.com

Internet: www.dungs.com

Head of oce and factory

The Pressure Equipment Directive (PED) and the Energy Performance of Buildings Directive (EPBD) require a periodic inspection of heat generators in order to ensure a high degree of eciency over a long term and, consequently, the least environmental pollution.

Safety relevant component Designed Lifetime CEN-Standard

Operating cycles

Time [years]

Valve proving systems 250.000 10 EN 1643

Gaz Pressure switch 50.000 10 EN 1854

Air Pressure switch 250.000 10 EN 1854

Low gas pressure switch N/A 10 EN 1854

Automatic burner control

250.000 10

EN 298 (Gaz)

EN 230 (Oil)

Flame detector (UV probes)

N/A

10.000

Operating

hours

---

Gas pressure regulators

N/A 15

EN 88-1 EN 88-2

Gas valve with valve testing system

after error detection

EN 1643

Gas valve without valve testing system

50.000 - 200.000

depends on diameter

10 EN 161

Gas-air ratio control system

N/A 10

EN 12067-2

EN 88-1

Performance decrease due to ageing

Gas families I, II, III

N/A not applicable

It is necessary to replace safety-relevant components after they have reached the end of their useful life:

We reserve the right to make modications in the course of technical development.

Subsidiary

Karl Dungs Limited

18, Liberty Way Attleborough Fields Ind. Est. GB-Nuneaton CV11 6RZ Großbritannien / Great Britain Phone +44 (0)24/76 37 57 33 Fax +44 (0)24/76 34 28 52 e-mail: info.gb@dungs.com

Internet: www.dungs.com

Dungs FRM 100025, FRM 100050 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual